Transcript
OFFICIAL USE for ASC & Sales Shop
T
ECHNICAL INFORMATION
Model No.
DDF481
Description
18V Cordless driver drill
PRODUCT P 1/ 11 L
CONCEPT AND MAIN APPLICATIONS
Model DDF481 is a supreme class cordless driver drill powered by 18V Li-ion battery of BL1815N (1.5Ah)/ BL1820 (2.0Ah)/ BL1830 (3.0Ah)/ BL1840 (4.0Ah)/ BL1850 (5.0Ah) . Its main features are: • Max lock torque: 125N.m. (1,090in.lbs) • Compact tool size with an overall length of 205mm (8-1/8") • Efficient Brushless DC motor provides higher power and productivity than that of 18V Cordless driver drill model BDF458/DDF458. Note: BL1815 is not compatible.
Specification Battery
Voltage: V Capacity: Ah Energy capacity: Wh Cell Charging time (approx.): min.
Max output: W No load speed: min.ˉ¹= rpm
High Low
Capacity of drill chuck: mm (") Capacity: mm (")
Steel Wood
Torque setting Clutch torque setting: N.m (in.lbs) Max lock torque: N.m (in.lbs) Max fastening torque: N.m (in.lbs)
Soft joint Hard joint
Electric brake Mechanical speed control Variable speed control Reversing switch LED job light
H W Dimensions: mm (") Length (L) 205 (8-1/8) Width (W) 79 (3-1/8) 249 (9-3/4)*1 Height (H) 266 (10-1/2)*2 *1: with BL1815N or BL1820 *2: with BL1830, BL1840 or BL1850
18 1.5, 2.0, 3.0, 4.0, 5.0 27, 36, 54, 72, 90 Li-ion 15, 24, 22, 36, 45 with DC18RC 640 0 - 2,100 0 - 550 1.5 (1/16) - 13 (1/2) 13 (1/2) 76 (3) 21 stage + drill mode 1.0 - 10.0 (9 - 89) 125 (1,090) 60 (530) 115 (1,020) Yes Yes (2 speed) Yes Yes Yes
Weight according to EPTA-Procedure 01/2003*3: kg (lbs)
*3: with Grip assembly
Standard equipment
Battery*4 Charger*4 Battery cover*5 + – bit 2-45 Belt clip (+) Screw M4x12 Grip assembly Bit holder Plastic carrying case *4: Battery and charger are not supplied with “Z” model *5: Supplied with the same quantity of extra Battery Note: The standard equipment may vary by country or model variation.
2.4 (5.2)*1 2.6 (5.8)*2
Optional accessories
Fast charger DC18RC Charger DC18SD Charger DC24SC Automotive charger DC18SE Quad Port Charger DC18SF Battery BL1815N Battery BL1820 Battery BL1830 Battery BL1840 Battery BL1850
Drill bits for wood Drill bits for steel Driver bits Belt clip Bit holder
P 2/ 11
Repair
CAUTION: Repair the machine in accordance with “Instruction manual” or “Safety instructions”.
[1] NECESSARY REPAIRING TOOLS
Code No. Description Use for 1R264 Torque wrench removing Drill chuck 1R291 Retaining ring S and R pliers removing Retaining ring (INT) R-15 1R298 Hex bar 10 with square socket removing Drill chuck removing Drill chuck (If it is impossible to remove Drill chuck by the steps 1R359 Chuck removing tool mentioned here) 1R404 Drill chuck removing tool removing Drill chuck without disassembling Gear assembly 1R404-A Frame assembly 1R404-B Frame support 1R404-C Pinion gear complete the components of Drill chuck removing tool (1R404) 921477-5 M8x55 Hex bolt 922127-5 M4x16 Hex socket head bolt --Hex wrench 10 removing Drill chuck
[2] LUBRICATION It is not required to lubricate, because this product has gear mechanism of factory assembled.
[3] DISASSEMBLY/ASSEMBLY [3] -1. Drill chuck
Fig. 1
DISASSEMBLING Note: When Gear assembly is replaced with a new one, separate Drill chuck from Gear assembly in advance. When the repair is independent of Gear assembly, it is not necessary to separate Drill chuck from Gear assembly. 4x18 Tapping (1) Remove four 4x18 Tapping screws, and then separate Gear assembly from screw (4 pcs.) Housing set. (Fig. 1) (2) Remove M6x22 (-) Flat head screw by turning it clockwise with Slotted screwdriver. Fig. 2 Note: Use Impact driver to unscrew M6x22 (-) Flat head screw if it cannot be M6x22 (-) flat head screw removed manually. (Fig. 2) Drill chuck (3) Engage 1R404-C with Gear teeth in Gear assembly. (Fig. 2) (4) Fit two Pins 4 of 1R404-A into the holes of Gear assembly. (Fig. 3) Gear assembly Secure Gear assembly to 1R404-A by tightening two 922127-5. (Fig. 3) 1R404-C Be careful about each direction. (Figs. 3 and 4) (5) Assemble 1R404-B to 1R404-A so that the lever portion of Gear assembly can be pushed toward 1st gear position. (Fig. 5) Fig. 3 Fig. 4 Note: Face the flat surface of the shaft of 922127-5 Lever portion of Gear assembly 1R404-C to the threaded hole in (2 pcs.) 1R404-B, and pass the shaft through Pin 4 (2 pcs.) of the hole of 1R404-B. (Fig. 6) 1R404-A Fig. 5 921477-5 (2 pcs.) 1R404-B 1R404-A Wide side 1R
404
Narrow side Fig. 6 Face the flat surface to M5x10 Thumb screw.
Lever portion of Gear assembly
Shaft of M5x10 Thumb screw 1R404-C of 1R404-B
1R
404
1R404-A
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Repair [3] DISASSEMBLY/ASSEMBLY [3] -1. Drill chuck (cont.) DISASSEMBLING
Fig. 7
R 4 0 4
Keep 1R404-B parallel with 1R404-A.
Set Gear assembly in drill mode.
1
(6) Set the lever portion of Gear assembly to 1st gear position. (Fig. 6) 1R404 Set Gear assembly in drill mode. (Refer to Fig. 7.) Tighten two 921477-5 evenly while keeping 1R404-B parallel with 1R404-A, and then tighten M5x10 Thumb screw of 1R404-B. (Fig. 6) (8) Hold 1R404 in Vise as drawn in Fig. 7. Secure 1R298 to Drill chuck and attach 1R264 to 1R298. (Fig. 8) narrow (9) Turn 1R264 counterclockwise to remove Drill chuck. (Fig. 8) side Note: When it is impossible to remove Drill chuck, try the steps with 1R359 mentioned in Makita repair tool list. Fig. 6 Fig. 8
wide side
M5x10 Thumb screw
1R264 1R298 1R404 1 R 4 0 4
1R404-A Lever portion of Gear assembly
Shaft of 1R404-C 1R404-B 921477-5 (2 pcs.)
Vise
ASSEMBLING Assemble by reversing the disassembly procedure. Note: • When you turn 1R264 clockwise to assemble Drill chuck to Spindle, the tightening torque should be 65 up to 72.5 N∙m (660 up to 740 kgf∙cm). • M6x22 (-) flat head screw is thread locker type, and therefore, apply ThreeBond 1342/ Loctite 243 to the thread and tighten the screw using Cordless impact driver with slotted bit.
[3] -2. Gear assembly, Rotor, Stator assembly, Speed change lever assembly DISASSEMBLING
Fig. 9 (1) Remove nine Bind PT3x14 tapping screws and four 4x18 Tapping screw, and then separate Rear cover and Housing R from Housing L. (Fig. 1 of the previous page and Fig. 9) (2) Remove the following parts from Housing L at a time. (Fig. 10) • Gear assembly with Drill chuck • Motor section • Speed change lever assembly (3) Remove Speed change lever assembly from Gear assembly, and then separate Motor section from Gear assembly. (Fig. 11) Housing L (4) Put Rotor section on a workbench so that the drive end of Rotor touches the workbench. Press Stator down to separate from Rotor. (Fig. 12) Fig. 10 Speed change lever assembly
Motor section
Gear assembly
Fig. 11
Rear cover
Housing R
Fig. 12 Rotor
Stator
4x18 Tapping screw (9 pcs.)
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Repair
Fig. 13
[3] DISASSEMBLY/ASSEMBLY [3] -2. Gear assembly, Rotor, Stator assembly, Speed change lever assembly (cont.) Caution for Handling of Rotor When handling or storing multiple Rotors, be sure to keep a proper distance between Rotors as shown in Fig. 13 because Rotor is a strong magnet, failure to follow this instruction could result in: • Finger injury caused by pinching between Rotors pulling each other • Magnetic loss of Rotors or damage on the magnet portion of Rotor. (Fig. 14)
Fig. 14 * Magnetic loss of Rotors * Damage on the magnet portion of Rotor
ASSEMBLING (1) Put Rotor into Stator complete as drawn in Fig. 15. Fig. 15 1. Holding Stator complete on a workbench, insert Rotor slowly in Stator complete until Rotor’s drive end reaches the workbench.
2. When the drive end of Rotor reaches the workbench, lift up Stator complete slowly.
Rotor Stator complete
(2) Make sure that Rotor’s gear engages with the super gears of Gear assembly to rotate them smoothly, and push Rotor section (Rotor and Stator) fully in Gear assembly, (Fig. 16) (3) Assemble Speed change lever assembly as drawn in Fig. 17.
Fig. 16
Fig. 17 Pin on the lever of Gear assembly
Stator
front Compression spring 4
Gear assembly
Drill chuck side 1. Apply the front Compression spring 4 of Speed change lever assembly to the flat side (without pin) of Gear assembly for Speed change.
Drill chuck side Space between the rear Compression spring 4 and the pin on the lever of Gear assembly
The front Compression spring 4 compressed by the lever of Gear assembly.
2. Push Speed change lever assembly toward Rotor side until it stops to have space between the pin of Gear assembly and the rear Compression spring 4.
3. Fit the pin of Gear assembly to Spring’s coil with slowly returning Speed change lever Drill chuck assembly toward Drill chuck side. side Pin on the lever of Gear assembly for fitting into the coil of the rear Compression spring 4.
4. Slide Speed change lever assembly to High speed mode: (Position 2 shown on Housing: Refer to Fig. 20 in the next page.)
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Repair [3] DISASSEMBLY/ASSEMBLY [3] -2. Gear assembly, Rotor, Stator assembly, Speed change lever assembly (cont.)
(4) Assemble Motor section with Gear assembly and Speed change lever assembly to Housing L at a time. And assemble Switch and F/R change lever to Housing L. (Fig. 18) Then, assemble Housing R to Housing L. (5) Assemble Rear cover to Housing set. (Figs. 19 and 9) and tighten nine PT3x16 Tapping screws to fasten Housing L, Housing R and Rear cover. Fig. 18 Make sure that two Leaf springs are set in place in advance.
Speed change lever assembly
Other side viewed from Housing L
Leaf spring (2 pcs.) Depressions
Fit the protrusions of Housing L into the depressions of Stator complete Terminal of Stator must be on the center line of Motor section and Gear assembly.
F/R Change lever Before assembling Switch to Housing L, fit the prong of F/R change lever to the projection of Switch. prong portion projection Fig. 19
Protrusion on Housing R Depression in Rear cover
Fit the depression in Rear cover into the protrusion on Housing R.
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Repair [3] DISASSEMBLY/ASSEMBLY [3] -2. Gear assembly, Rotor, Stator assembly, Speed change lever assembly (cont.)
Note: • Be sure to route the lead wires for LED circuit to the space between ribs of Gear assembly after setting Gear assembly in place. (Fig. 20) If the routing is done before assembling Gear assembly, the breakage or pinching of the lead wires will happen. • When Housing L are fastened to Housing R, the clearance is left because of the existence of Gear assembly in Housing L and Housing R. Therefore, clamp them with a waterpump pliers carefully. (Fig. 21.) Fig. 20
Fig. 21 Clamp the designated positions carefully not to leave the clearance between Housing L and R when tightening PT3x16 Tapping screws.
Lead wires for LED circuit Ribs of Gear assembly
[3] -3. Grip assembly DISASSEMBLING
Fig. 22 Refer to Fig. 22 for the components of Grip assembly. The components of Grip assembly (1) Remove Retaining ring (INT) R-15 with 1R291. Pole complete (2) Remove M8x65 Hex bolt from Pole complete by turning the bolt counterclockwise. (3) Remove Arm R complete from Arm L. (4) Remove Arm L from Pole complete by turning the arm Arm L Arm R complete Retaining ring clockwise. (INT) R-15 Note: Grip assembly for DHP481 has M5x10 Thumb screw and M5 Hex nut, and therefore, the grip is different from that of DDF481. Loosening the thumb screw will cause the M5 Hex nut to be removed from Arm L. M5x10 Be careful about the loss of the M5 Hex nut when Thumb screw M5 Hex nut M8x65 Hex bolt DHP481 is disassembled. (for DHP481 only) (for DHP481 only) ASSEMBLING (1) Screw Pole complete in Arm L to the full. (2) Insert the rod of Arm complete R into the hole of Arm L. (Fig. 23) (3) Connect the male thread of M8x65 Hex bolt with the female thread of Pole complete as drawn in Fig. 24. (4) Set Retaining ring (INT) R-15 in place of Arm R complete. Fig. 23 Hole of Arm L Rod of Arm R complete
Fig. 24 Five to six turns of the thread of M8x65 Hex bolt must be connected with Pole complete before DDF481/ DHP481 is setting in place.
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Circuit diagram Fig. D-1 Color index of lead wires' sheath Purple Yellow Brown Orange Gray Blue
Black White Red
Stator complete
Switch
LED circuit
Controller
Terminal
Red lead wire is used for some country instead of white.
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Wiring diagram Fig. D-2 View before setting Switch and F/ R change lever in place Place Connector this space among Rib A, Rib B and Boss.
Rib A
Stator
A’
Thick lead wires from Stator must be put on the other thin lead wires.
LED circuit
A
See the following illustration for the cross section between A and A’.
Rib B Boss
Front view around the lead wires for LED circuit after setting Gear assembly in place Note: Be sure to route the lead wires for LED circuit to the space between ribs of Gear assembly after setting Gear assembly in place. If the routing is done before assembling Gear assembly, the breakage or pinching of the lead wires will happen.
Lead wires for LED circuit
Ribs of Gear assembly
LED circuit (Insert it as drawn above,)
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Wiring diagram Fig. D-3
Switch Lead wire (white) Flag terminal Set Flag terminal to Switch as shown above.
Stator complete Thick lead wires from Stator complete must be put on the other thin lead wires for the designated area .
Boss A Rib C
Lead wires from Stator complete must be routed between Boss A and Rib C.
Boss B
Lead wire (Red) from Terminal must be; • placed under Lead wires from Stator complete • routed between Rib D and Rib E.
Do not put any lead wires on these ribs.
Rib of Controller
Rib E Controller
Rib D
Rib E
The slack of Lead wire (Red) from Terminal must not be piled on/under Capacitor of Controller. Lead wires from Terminal must be placed under Rib of Controller. Capacitor of Controller
Terminal
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Trouble shooting Whenever you find any trouble in your machine, first, refer to this list to check the machine for solution.
Note in Repairing (1) Use the full charged battery which has the star mark. (Fig. D-4) (2) When Housing is disassembled, check the conditions of the electrical parts (Connectors, Lead wires, Switches, etc.), Armature, Stator, Gear section, etc. (3) Do the running test in Low speed mode (when the trigger is being pulled just a little) to check the following functions by repeating 10 times; • F/R change lever • Operation mode change ring • High/Low speed change lever • Variable speed control trigger
Fig. D-4 Star mark
Check List for Trouble Shooting Check the items from the top of the following list. (Description of the item is referred to Circuit diagram in Fig. D-1.) Change Stator complete if your problem cannot be solved although its corrective action has been carried out. Symptom
Cause
LED indicator lamps are on.
No
Rotation speed can be changed. Forward/ Reverse rotation are OK
No
Controller is broken.
Yes
Yes
Yes
Motor runs when the machine is switched on. In case of running inconstantly, go to “No”.
No
LED job light are on.
No
Yes The machine does not have any trouble.
LED indicator lamps are on.
No
Yes
LED job light are on.
No
Yes
Yes
No
Replace Stator complete. (See the next page.)
Connectors are in incomplete connection.
Connect it firmly.
Lead wires are broken.
Check Lead wires, or replace it.
Switch is broken.
Replace Switch.
Connectors are in incomplete connection.
Connect it firmly.
Lead wires are broken.
Check Lead wires, or replace it.
LED circuit is broken.
Replace LED circuit.
Switch is broken.
Replace Switch.
Switch is broken.
Replace Switch.
Terminal is broken.
Check Terminal, or replace it.
Controller is broken.
Replace Stator complete.
Connectors are in incomplete connection.
Connect it firmly.
Lead wires are broken.
Check Lead wires, or replace it.
Switch is broken.
Replace Switch.
LED is broken. Rotor is rubbed to Stator.
Corrective action
Replace LED.
Controller is broken.
Replace Stator complete. (See the next page.)
Rotor is broken.
Replace Rotor.
Stator is broken.
Replace Stator complete.
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Trouble shooting Test for recognizing the trouble on FET (Field effect transistor) in Controller
(1) Set Digital tester (1R402) in the diode mode ( mark on the tester: Refer to Fig. D-5.) (2) Switch, Terminal, Controller and Stator are connected each other as drawn in Fig. D-6. Do the following steps. Test 1: Attach Black tester bar to the terminal of white lead wire end on B1 terminal of Switch. (Fig. D-7.) Attach Red tester bar to one of UVW terminal connected with Red, White, Blue lead wires. (Fig. D-8) Check the figure in the tester. Test 2: Attach Red tester bar to minus terminal of Terminal (connected with black lead wire). (Fig. D-9) Attach Black tester bar to one of UVW terminal connected with Red, White, Blue lead wires. (Fig. D-10) There is no fault on FET of Controller if the tester indicates within 0.39V - 0.41V in both Test 1 and Test 2. If either Test 1 or Test 2 results in the improper figure, Controller is broken. Change Stator complete. Fig. D-5
Fig. D-6 Stator complete (A modular part of Controller, lead wires and Stator)
Terminal
Fig. D-7
Fig. D-8
Stator complete
Switch Black tester bar
Fig. D-9
Red tester bar
Fig. D-10 Stator complete Controller (the component of Stator complete) Black tester bar
Red tester bar
Terminal
Switch
